Compostable insulation for shipping container

ABSTRACT

A thermal insulation article includes a thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container. The pad includes a solid compostable panel formed primarily of starch and/or plant fiber pulp that holds together as a single unit, and a water-proof or water-resistant film forming a pocket enclosing the panel. The panel includes a first section, a second section, and a third section connecting the first section to the second section, the first and second section each having a central portion and two flaps that extend from the central portion beyond the third section, and wherein the panel is foldable into an open box.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 62/460,023, filed Feb. 16, 2017, the entire disclosure of whichis incorporated by reference.

TECHNICAL FIELD

This invention relates to an insulating pad for a shipping container,and more particularly where the insulating material is compostable.

BACKGROUND

A conventional container for shipping temperature sensitive productsincludes a cardboard box, inside of which is a thermally insulatingmaterial. A conventional thermally insulating material is expandedpolystyrene (EPS), e.g., Styrofoam. For example, panels of the expandedpolystyrene can line the walls of the box, and another packing material,e.g., bubble wrap, can be placed surround and cushion the item beingshipped inside the panels. Alternatively, expanded polystyrene can bemachined or molded to form a “cooler” into which the item being shippedcan be placed—this does not need an external box. In either case, acoolant, e.g., ice, dry ice or a gel pack, is placed in the cavity inthe box with the item being shipped.

EPS is relatively inexpensive and easily formed into a variety ofshapes, but is not compostable. Consequently, disposing of the materialof the container can be a problem.

SUMMARY

Packaging material is described that provides for thermal insulation ofan item being shipped while the components are still recyclable orcompostable.

In one aspect, a thermal insulation article includes a thermallyinsulating pad shaped to be positioned in a cavity of a rectangularprism shipping container. The pad includes a solid compostable panelformed primarily of starch and/or plant fiber pulp that holds togetheras a single unit, and a water-proof or water-resistant film forming apocket enclosing the panel. The panel includes a first section, a secondsection, and a third section connecting the first section to the secondsection, the first and second section each having a central portion andtwo flaps that extend from the central portion beyond the third section,and wherein the panel is foldable into an open box with the narrowsection providing a floor of the box, central portions of the first andsecond section providing opposing first and second side walls of box, afirst pair of flaps from the first and second section providing a thirdside wall of the box, and a second pair of flaps from the first andsecond section providing a fourth side wall of the box opposite thethird side wall.

Implementations may include one or more of the following features.

The panel may be formed of a material sufficiently soft to be manuallyfolded. The panel may be scored to assist at least some folds. The panelmay be scored at a connection of the third section to the first sectionand scored at a connection of the third section to the second section.The panel may be scored at a connection of each respective flap torespective central sections. The panel may be scored across a midline ofthe third section such that the panel is configured to be folded inhalf. The panel may be folded in half and may occupy about half of thepocket formed by the film. The panel may be scored with a score thatextends partially but not entirely through the thickness panel. Thescore may be a compressed portion or a cut out portion of the panel.

The two flaps that extend from the central portion may be a first twoflaps, and the first and second section may each have a second two flapsthat extend from the first two flaps. The second two flaps may befoldable inward to overlap a portion of the floor provided by the thirdsection. The panel in an unfolded position may include a pair ofT-shaped cuts on opposing edges of the panel. The panel in an unfoldedposition may have a pair of recesses on opposing edges of the panel, therecesses defining the third section as narrower than the first sectionand the second section. A width of each of the two flaps may be one-halfto one times of a width of the third section between the first sectionand the second section.

The panel may be formed primarily of starch, e.g., a grain starch, aroot starch, a vegetable starch, or combinations thereof. The panel maybe formed primarily of plant fiber pulp, e.g., fibers from wood, corn,cotton, coconut or flax, or combinations thereof. The panel may have auniform homogenous composition. The panel may be a single unitary body.The panel may have a thickness between of about ¼ and 1 inch. One ormore surfaces of the panel may be corrugated.

The film may be water-proof. The film may be compostable. The film mayinclude polyethylene or paper. A water-resistant or water-proof coatingmay be formed on the paper. The coating may include wax.

In another aspect, a method of assembling a thermal insulation articleincludes unfolding a solid compostable panel formed primarily of starchand/or plant fiber pulp that holds together as a single unit while thepanel is contained within a pocket of a water-proof or water-resistantfilm; and refolding the solid compostable panel into a container thathas an opening at top while the panel is contained within the pocket.

Implementations may include one or more of the following features.

After refolding, a portion of the film may be pushed into the opening onthe top of the container such that the film lines an interior and anexterior of the container. Refolding may include folding along scoresformed in the panel.

Potential advantages may include (and are not limited to) one or more ofthe following.

The insulating material of the packaging material is compostable, andthe film containing the insulating material is compostable or recyclableand also easily disposed. The packaging is easy to assemble, and can bemanufactured at low cost. The packaging can provide equivalent thermalinsulation to expanded polystyrene, and can be disposed in commercialand residential composting or recycling bins or garbage cans. Thecontainer components can be shipped in bulk in an unassembled state withminimal cost increase, and assembly of the container can be performed bythe user.

The details of one or more embodiments are set forth in the accompanyingdrawings and the description below. Other features, objects, andadvantages of the invention will be apparent from the description anddrawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is an exploded perspective view of an example of an insulatedshipping container.

FIGS. 2A-2G illustrate an example of construction of the pads of theinsulating shipping container of FIG. 1.

FIGS. 3A-3I illustrate an example that includes two three-sectioned padsfor the insulating shipping container.

FIGS. 4A-4D illustrate an example that includes six individual pads forthe insulating shipping container.

FIGS. 5A-5H illustrate an example that includes a three-sectioned padand three individual pads for the insulating shipping container.

FIG. 6 illustrates an example that includes a single six-sectioned pad.

FIGS. 7A and 7B illustrates an example of multiple multi-section panelsenclosed in a water-proof film, in an unfolded and folded state,respectively.

FIG. 8 illustrates an example of using solid compostable panels, withouta water-proof film, for an insulated shipping container.

FIG. 9 illustrates multiple panels that are laminated together.

FIGS. 10A and 10B are a plan view and a cross-sectional side view,respectively, of a pad.

FIG. 11 is a plan view of a panel from the pad assembly of FIGS. 10A and10B.

FIG. 12 illustrates a method of assembly of the pad.

FIGS. 13A-13C are composite perspective and cross-sectional viewsillustrating a method of assembling packaging for a shipping container.

FIG. 13D is a cross-sectional view illustrating a method of assemblingpackaging for a shipping container.

FIG. 14 is a plan view of another implementation of a panel.

FIG. 15 is composite perspective and cross-sectional views illustratinga method of assembling packaging for a shipping container.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Initially, some terminology may be beneficial. “Biodegradable” simplymeans that a product will eventually disintegrate into to innocuousmaterial. “Recyclable” indicates that a product can be reused or treatedin order to be made suitable for reuse. “Compostable” indicates boththat a product will decompose quickly, e.g., within 180 days, and thatthe product will decompose into material that can be used as fertilizer(e.g., per ASTM D6400 or EN 13432). Products that are “biodegradable”need not be (and usually aren't) “compostable.” First, since there is noparticular time limit for a “biodegradable” product to disintegrate, itneed not decompose quickly. For example, even aluminum cans willbiodegrade given several centuries. Moreover, even a biodegradableproduct that decomposes quickly might not provide a material that issuitable as fertilizer.

Most conventional thermally insulating materials for packaging, e.g.,EPS, are not compostable. One technique for using a compostableinsulating packaging material is to fill a volume between an inner walland an outer wall of a box with loose-fill compostable cornstarch foampellets (e.g., packing “peanuts”) using layered stratification, and thencompress each layer of foam pellets in within this volume to compactthem. This technique requires either multiple boxes or a specialized boxhaving both inner and outer walls, and also requires specializedmachinery for layered stratification compaction of the pellets. Theadditional or specialized boxes increase the cost. In addition, theloose fill pellets are difficult to compost because they are messy whenremoved from the box. Moreover, a large amount of pressure, e.g., 25lbs. or more, needs to be applied to close the top flaps of the box dueto the resistance from the pellets. However, instead of loose-fill foampellets, a solid compostable panel formed primarily of extruded starch,e.g., milled extruded sorghum, can be enclosed by a biodegradable orcompostable film to provide a thermally insulating pad, and this pad canbe used as the insulating packaging in the container.

FIG. 1 is an exploded perspective view of an example of an insulatedshipping container 10. The shipping container 10 includes a box 20 andone or more thermally insulating pads 30 that fit inside an interiorcavity 22 of the box 20. The thermally insulating pad(s) 30 are shapedsuch that when positioned in the box 20 they provide an interior spaceto receive the item and optionally a coolant, e.g., ice, dry ice or agel pack.

The box 20 can be a rectangular prism, and can includes rectangular sidewalls 24 that define the interior cavity 22. The bottom of the box maysimilarly be closed off by one or more flaps (not shown due to theperspective view). The top of the box 20 provides an opening to theinterior cavity 22. A cover for the box 20 can be provided by one ormore flaps 26 that can be folded inwardly from the side walls 24 toclose off the top of the cavity 22. In some implementations, the sidewalls 24, flaps 26 and bottom of the box are all part of a singleintegral sheet that is folded into an appropriate shape. Alternatively,the cover for the box 20 can be provided by a separate lid that fitsover the side walls 24.

The box 20 is a recyclable material. For example, the box 20 can be acardboard box, e.g., paper board or corrugated cardboard.

As noted above, the container includes one or more thermally insulatingpads 30 that fit inside the box 20. Each pad 30 is formed by sealing acompostable insulating material within a recyclable and biodegradablefilm or compostable film. The film can be water-resistant, water-proofor water-repellant.

The compostable insulting material can be in the form of a solid panel(or multiple solid panels). The panel could be a foam material.

The panel can be relatively inflexible and incompressible, e.g., similarto expanded polystyrene packaging (e.g., Styrofoam™). For example, thepanel can have a Young's modulus greater than 1 GPa, e.g., 1-5 GPa.

Alternatively, the panel can be flexible and compressible. For example,the panel can have a Young's modulus less than 1 GPa, e.g., 0.01-1 GPa.In this case, the panel is effectively a pillow or cushion.

The compressibility and flexibility of the panel can be set bycontrolling the heat and compression used during extrusion of thematerial, in conjunction with material characteristics such as fiber orparticulate size, composition and presence of additives such asadhesive.

In some implementations, the pad includes a single panel. Each pad 30 isrelatively thin, e.g., about 0.25-4 inches thick, as compared to thelength and width of the pad. The thickness of a pad 30 is considered tobe along its narrowest dimension, whereas the length and width of thepad 30 are considered to be along the two directions along the primaryface, perpendicular to the thickness.

Each panel can be formed primarily of starch, e.g., an extruded starch,and/or organic fiber pulp. The starch can be a grain starch, e.g., cornstarch, wheat starch or sorghum (sorghum is also known as milo), a rootstarch, e.g., potato starch, a vegetable starch, or combinationsthereof. The organic fiber pulp can be a plant fiber pulp, e.g., paperpulp, or pulp from vegetable products, e.g., corn husks, cotton, coconutshell, flax, etc.

A panel formed of organic fiber pulp can be formed by injection moldingor compaction, e.g., compacted paper pulp. Other materials that do notinterfere with the compostable nature of the panel, e.g., a softener toimprove adhesion of the starch, or a preservative or anti-fungal agent,can be present, but only in small quantities. For example, at least 85%,e.g., at least 90-95%, by weight of the panel is starch and/or organicfiber pulp. Polyvinyl alcohol can be present, e.g., 5-10% by weight.

Each panel is “solid”, which in this context indicates that the panelholds together as a single unit, rather than being formed of loose-fillpellets. It may be noted that compressed starch pellets would not form asolid part; upon removal of pressure the pellets would disassemble, andincreased pressure only fractures or pulverizes the pellets. A solidpanel of extruded starch provides significant thermal insulation, whilestill being compostable.

It is possible for the panels to be a foam material, e.g., to includesmall pores or voids spread substantially uniformly through the panel.For example, 10-80% of the volume of the panel can be pores or voids,e.g., 25-75%, 25-50%, 10-25%, 50-75%. The maximum size of the pores orvoids can be about 1 mm. The density of a panel can be about 0.4-3.5g/cm³, e.g., 0.6-1.0 g/cm³, 0.8-2.0 g/cm³, 1.0-3.5 g/cm³.

Each panel can be of a uniform homogenous composition. Furthermore, eachpanel can be a unitary body—that is the body of the panel holds togetherby itself without adhesives or fasteners to join multiple sectionstogether to form the panel.

Although the panel is thin, as compared to the length and width of thepanel, the panel (or stack of panels) is thick enough to providesufficient thermal insulating function for common commercialapplications that require shipment of products, e.g., foods or medicalsupplies. The thickness of a panel can be about 0.25-1.0 inches, e.g.,0.25-0.75 inches.

Any given panel can have substantially uniform thickness across itsprimary surface. The surfaces of the panel can be generally flat, or oneor more surfaces can be corrugated. Corrugation can increase theeffective thickness of the pad, e.g., by a factor of up to 4. In thiscase, the thickness of the panel can still be uniform, but the panel isshaped with corrugations.

Each panel can include one or more rectangular plates dimensioned tosubstantially span whichever of the floor, plurality of side walls orcover that the rectangular plate is adjacent. In some implementations,the whole of the panel, when in an unfolded configuration, is alsorectangular.

The panels can be formed by an extrusion process. After extrusion, eachpanel can be cut to the appropriate size. In addition, the edges canoptionally be beveled as to provide the beveling of the pads describedabove. In addition, the panel that provides the collar can be scored, asdescribed below.

The film can be a plastic film. In some implementations, the film isair-tight.

In some implementations, the film is compostable, e.g., a bioplasticthat meets ASTM D6400 standards. Suitable materials for a compostablefilm include polymers based on one or more of polylactic acid (PLA),poly(beta-amino) esters (PBAE), polyhydroxyalkanoate (PHA),polycapralactones (PCL), polybutyrate adipate terephthalate (PBAT)polyvinylalcohol (PVA), or ethylene vinyl alcohol (EVOH). For example, acombination of PBAT and PE may be suitable. As another example, acombination of PE and PLA may be suitable. In some implementations, thepolymer can be mixed with an organic product, e.g., a starch, such ascorn starch.

In some implementations, the film is recyclable and biodegradable. Asuitable material for the recyclable film is polyethylene orpolypropylene. For example, the film can be a low-density polyethylene(LDPE), a medium-density polyethylene (MDPE), a high-densitypolyethylene (HDPE) or polyethylene terephthalate. An advantage ofpolyethylene is ease of fabrication and good water resistance.

In some implementations, the film is a paper sheet. If the paper is thinenough or is perforated, the paper is compostable. Optionally, the papercan be lined with a water-repellant coating. Either the inner surface ofthe film, or the outer surface, or both can be lined with thewater-repellant coating. The water-repellant coating can be acompostable material, e.g., wax. In this case, the film with paper andcoating is compostable. Alternatively, the water-repellant coating canbe a recyclable material. In this case, the film with paper and coatingis recyclable.

A problem with starch-based insulation is that it dissolves easily inwater. If the item being shipped is cold or a coolant is placed in theinterior of the container 10, condensation can form on the interiorsurfaces of the pad 30. However, a water-proof or water-resistant filmprevents liquid, e.g., the condensation, from reaching the starch panel,thus enabling the starch panel to be usable as a thermal insulator inthe container.

To fabricate a pad 30, the starch panel can be placed between two sheetsof the film. The edges of the film can be heat-sealed to each other,e.g., along the entire perimeter of the panel, thus enclosing andsealing the panel in a pocket of the compostable or recyclable film thathas only slightly larger dimension than the panel itself. A suitablesealing temperature is above 100° C. Excess film outside the heat sealcan be cut away.

In the directions parallel to the primary surface of the panels, thepocket can be up to about 0.5 inches larger on each side than the panel.

Alternatively, the film can be provided in a tubular form. To fabricatea pad 30, the panel is slid inside the tube of film, and the two openends of the tube are heat sealed. This forms a pocket in which the panelsits.

In some implementations, the panel sits loose inside the pocket formedby the film. That is, the panel is not bonded or otherwise fixed to thefilm. Thus, the panel can slide inside the pocket relative to the film.For example, the film can be in sliding contact with the panel. Theinterior of the pocket can include a small amount of air. In someimplementations, the air is vacuumed out before the pocket is sealed.

In some implementations, the panel is affixed to the film. For example,the film can be secured to the panel by heat bonding the film to thepanel. As another example, the film can be secured to the panel by anadhesive. The adhesive can be a separate additive, or the adhesive canbe provided by applying water to the panel to cause the starch in aportion of the panel at the surface to become tacky such that the filmsticks to the panel.

In some implementations, the film directly coats the panel. The filmthat directly coats the panel can be composed of an organic compostablematerial, e.g., a wax. The film can be spread in a thin layer on thesurface of the panel. The film can be applied in liquid form and thenharden on the panel. Alternatively, the film can be sprayed onto thepanel. For example, a water-repellant material can be sprayed onto thepanel.

The film can be affixed on both the interior and exterior surface of thepanel, or on just one surface of the panel, e.g., just the interiorsurface or just the exterior surface of the panel. In addition, for eachof the interior and exterior surface of the panel, the film can beaffixed across the entire surface, or on just a portion of the surface,e.g., a perimeter portion along the edge or a central portion that isspaced away from the edge of the panel.

Other than one or panels, there need not be any other thermallyinsulating material within the film. For example, unless one of thepanels fractures due to applied stress, there are no loose pellets orpieces of other insulating material in the volume enclosed by the film.In some implementations, the pad 30 consists of, i.e., includes only,one or more panels, the film, and optionally some air inside the volumeenclosed by the film.

Where both the panel and film are compostable, the entire pad can bedisposed of as a unit in a composting bin. Where the panel iscompostable and film is recyclable, the film can be ripped off the panelmanually by the recipient of the package, and then the panel can bedisposed of in a composting bin and the film can be disposed of arecycling bin.

In the implementation shown in FIG. 1, the thermally insulating pads 30include a bottom pad 32, a collar 34, and a top pad 36.

The bottom pad 32 has a length and width that match the bottom of thebox 20, or are slightly smaller, e.g., by about an ⅛ inch tolerance, sothat bottom pad 32 fits snugly at the bottom of the cavity 22 on thebottom of the box 20.

The collar 34 includes a single panel that is folded into four wallmembers 40. Each wall member 40 has a height (in the vertical direction)about equal to the height of the box 20, less the combined thickness ofthe top pad 32 and bottom pad 36. Each wall member 40 has a width (inthe lateral direction) that matches the adjacent side wall 24 of the box20, or is slightly smaller, e.g., e.g., by about an ⅛ inch tolerance.Thus, the collar 34 fits snugly into cavity 22 on top of the bottom pad32, with each wall member 40 adjacent, e.g., in contact with, one of theside walls 24.

The top pad 36 has a length and width that match the top of the box 20,or are slightly smaller, e.g., e.g., by about an ⅛ inch tolerance, sothat the perimeter of the top pad 36 can sits on the wall members 40 ofthe collar 34 and the top pad 36 itself fits snugly at the cavity 22.When the top of the box 20 is closed, e.g., by closing the flaps 26 orplacing a lid, the top pad 36 sits adjacent, e.g., in contact with, thetop of the box 20.

In some implementations, the surfaces of the pads 30 are basically flatup to and including their edges. “Basically flat” is used to indicateflat at the scale of the thickness of the pad, but still encompasses thepossibility of small scale surface texturing. Thus, the lower rim of thecollar 34 simply sits basically flat on the perimeter of the top surfaceof the bottom pad 32, and the perimeter of the top pad 36 simply sitsbasically flat on the upper rim of the collar 34. Alternatively, theinterior surfaces of each pad, i.e., the surface of the pad facing thecavity and further from the box 20, can be beveled at the edge that isadjacent another pad. Thus, the beveled lower rim of the collar 34 sitson the beveled perimeter of the bottom pad 32, and the beveled perimeterof the top pad 36 sits on the beveled upper rim of the collar 34. Inthis latter case, the outer surface of each wall member 40 can have aheight about equal to the height of the box 20.

FIGS. 2A-2G illustrate an example of construction of the pads 30 of theinsulating shipping container 10 shown in FIG. 1.

Referring to FIG. 2A, an exploded perspective view, the collar 34 can befabricated by forming a solid compostable panel 50 that has a length Lapproximately equal to or slightly less than the length of the lateralperimeter of the box 20, and a width W approximately equal or slightlyless than the height of the box 20. The panel 50 is then placed betweentwo sheets 60 of the compostable or recyclable film. Referring to FIG.2B, a cross-sectional side view, the two sheets 60 are heat sealed alonga path than extends around the entire perimeter of the panel 50. Theseal can be positioned no more than about 1 inch, e.g., no more thanabout ½ inch, from the edge of the panel 50. Excess film outside theheat seal can be cut away.

FIG. 2C is a cross-sectional side view, and FIG. 2D is a perspectiveview. Referring to FIGS. 2C and 2D, before or after sealing the panel 50between the sheets 60, one surface of the panel 50 (which will be theinward facing surface of the panel) can be scored in three locations todivide the panel 50 into four rectangular plates 52, which correspond tothe four side walls of the collar 34. The length of each plate 52corresponds to the width of the corresponding side wall 50 of the collar34. Scoring can be performed by compression with an angled rigid body.

Each score can create a recess 56 that extends across the width W of thepanel. The recess 56 extends partially, but not entirely through thethickness of the panel 50. For example, the recess 56 can extend throughabout 50-75% of the thickness of the panel 50. The scoring can beangled, so the recess has a triangular cross-section.

The reduced thickness of the panel 50 in the scored areas increases theflexibility of the panel so that the panel 50 can be bent at a rightangle without breaking. In particular, the panel 50 can be foldedinwardly (with the inside surface being the side with the recess 56).This permits the panel 50 to remain as a single unitary part when thecollar 34 is folded and placed in the box 20, which can improve thermalinsulation by reducing creation of gaps in the insulating material.

FIG. 2E is a schematic exploded perspective view. FIG. 2F is a schematiccross-sectional side view. FIG. 2G is a schematic perspective view.Referring to FIGS. 2E-2G, construction of the top pad 32 and bottom pad36 is even simpler. A panel 50 is formed having lateral dimensionsapproximately equal to or slightly less than the correspondingdimensions of the top or bottom the box 20. This panel 50 is then placedbetween two sheets 60 of the compostable or recyclable film (see FIG.2E), and the two sheets 60 are heat sealed along a path than extendsaround the entire perimeter of the panel 50 (see FIG. 2F) to provide thetop pad 32 or bottom pad 36. Excess film outside the heat seal can becut away.

FIGS. 3A-3I illustrate another example of construction of the pads 30for the insulating shipping container 10. In the example of FIGS. 3A-3I,rather than three pads, the thermally insulating pads 30 include a firstthree-sectioned pad 70 and a second three-sectioned pad 72.

FIGS. 3A and 3B are schematic exploded perspective views of the twothree-sectioned pads. FIGS. 3C-3F are schematic cross-sectional sideview of the two three-sectioned pads. FIGS. 3G and 3H are schematicperspective views of the two three-sectioned pads. FIG. 3I is aschematic exploded perspective view showing how the two three-sectionedpads are positioned relative to each other.

These pads 30 are constructed similarly to the pads discussed above forFIGS. 2A-2D, with each pad 70, 72 formed by sealing a solid compostablepanel within a compostable or recyclable film. In particular, eachthree-sectioned pad 70, 72 is constructed in a manner similar to thecollar 34 discussed above, but with scoring in two locations rather thanthree locations.

In particular, referring to FIG. 3A, the first three-sectioned pad 70can be fabricated by forming a solid compostable panel 50 that has alength L approximately equal to or slightly less than the length ofthree side walls of the box 20, and a width W approximately equal orslightly less than the height of the box 20. Referring to FIG. 3B, thesecond three-sectioned pad 72 can be fabricated by forming a solidcompostable panel 50 that has a length L approximately equal to orslightly less than the length of top and bottom of the box 20 plus theheight of one of the side walls of the box, and a width W approximatelyequal or slightly less than the lateral length of one of the side wallsof the box 20.

Referring to FIGS. 3A-3D, each panel 50 is then placed between twosheets 60 of the compostable or recyclable film, and the two sheets 60are heat sealed, as discussed above.

Referring to FIGS. 3E-3G, before or after sealing each panel 50 betweenthe sheets 60, one surface of the panel 50 (which will be the inwardfacing surface of the panel) can be scored in two locations to dividethe panel 50 into three rectangular plate 52, which correspond to thefour side walls of the collar 34. The length of the plates 52 of thefirst three-section pad 70 correspond to the width of the threecorresponding side walls of the box 20. The length of the plates 52 ofthe second three-section pad 72 correspond to the width of the top side,the length of the remaining side wall, and the width of the bottom side,respectively, of the box 20.

Together, the resulting two three-sectioned pads 70, 72 cover each ofthe six sides of the box 20 when inserted in the interior 22 of the box20.

It should be realized that other configurations are possible for the twothree-sectioned pads 70, 72. For example, the first three-sectioned padcould cover the bottom and two opposing sides of the box, and the secondthree-sectioned pad could cover the top and the other two opposing sidesof the box.

FIGS. 4A-4D illustrate yet another example of construction of the pads30 for the insulating shipping container 10. In the example of FIGS.4A-4D, rather than three pads, the thermally insulating pads 30 includesix pads 80, one for each of the six sides of the box 20.

FIG. 4A is a schematic exploded view of one of the pads. FIG. 4B is aschematic cross-sectional side view of one of the pads. FIG. 4C is aschematic perspective view of one of the pads. FIG. 4D is a schematicexploded perspective view showing how the two three-sectioned pads arepositioned relative to each other.

These pads 30 are constructed similarly to the pads discussed above forFIGS. 2E-2G, with each pad formed by sealing a solid compostable panelwithin the film. Each pad (and each panel of the pad) has a length andwidth appropriate for the dimensions of the associated side of the box20, along the lines discussed above.

The example of FIGS. 4A-4D does not require scoring, and consequentlycan be easier to manufacture. However, the increased number of gapscould decrease the effectiveness of the thermal insulation.

FIGS. 5A-5H illustrate still another example of construction of the pads30 for the insulating shipping container 10. In the example of FIGS.5A-5H, rather than three pads, the thermally insulating pads 30 includea three-sectioned pads 90, and three individual pads 92.

FIG. 5A is a schematic exploded perspective view of the three-sectionedpad. FIGS. 5B and 5C are schematic cross-sectional side views of thethree-sectioned pad. FIG. 3C is a schematic perspective view of the twothree-sectioned pad. FIG. 5E is a schematic exploded view of one of theindividual pads. FIG. 5F is a schematic cross-sectional side view of oneof the individual pads. FIG. 5G is a schematic perspective view of oneof the individual pads. FIG. 5H is a schematic exploded perspective viewshowing how the two three-sectioned pads are positioned relative to eachother.

Referring to FIGS. 5A-5D, the three-sectioned pad 90 is constructedsimilarly to the three-sectioned pads discussed above for FIGS. 3A-3F,with the pad 90 formed by sealing a solid compostable panel within acompostable or recyclable film. Referring to FIG. 5A, thethree-sectioned pad 90 can be fabricated by forming a solid compostablepanel 50 that has a length L approximately equal to or slightly lessthan the height of two side walls of the box 20 plus the length of thebottom of the box 20, and a width W approximately equal or slightly lessthan the width of one of the sides of the box 20.

Referring to FIGS. 5E-5G, the three individual pads 92 are constructedsimilarly to the top and bottom pads 32, 36 discussed above for FIGS.2E-2G, with the pads 92 formed by sealing a solid compostable panelwithin a compostable or recyclable film. Each pad 92 (and each panel ofthe pad) has a length and width appropriate for the dimensions of theside of the box 20 which it will line, as generally discussed above.

Although FIGS. 5A-5C show the three-sectioned pad having a centersection that corresponds to the bottom of the box, this is notnecessary. The center section could correspond to one of the side wallsor the top of the box.

Even further configurations are possible for the pads 30, provided eachwall of the box is provided with an individual pad or a section of apad. For example, there could be three two-sectioned pads, or athree-sectioned pad, two-sectioned pad and an individual pad.

Moreover, there could be just a single pad 100 that fits inside the box20 and covers all six sides of the box 20. For example, FIG. 6, which isa schematic top view of a pad 100 in an unfolded configuration,illustrates a single six-sectioned pad. To fabricate this six-sectionedpad 100, the panel can be formed in a “cross-shape”, or another shapethat when folded will correspond to the sides of the rectangular prismof the box 20. The panel is sandwiched between two sheets, as discussedabove, and the edges are sealed along a path that runs close to theperimeter of the panel. Excess material of the sheets can be cut off.The panel can be scored with cuts 56 in five locations to divide thepanel into six sections. The scoring corresponds to the positionsnecessary for the panel to be folded such that each section correspondsto one of the sides of the box 20. Although the implementation shown inFIG. 6 is for a cubical box, this is not required.

The example of FIG. 6 may provide improved good thermal insulation dueto fewer gaps, and there can be a convenience for the customer to havejust a single pad for each box. On the other hand, this configurationmay have a cumbersome form factor.

The box 20 and pad or pads 30 that form the insulated shipping container10 can be provided as an unassembled kit, and be assembled by acustomer. For example, the box 20 and pads 30 could be shrink-wrapped orotherwise sealed together in packaging.

In any of the various examples discussed above, one or more apertures,e.g., about ⅛ to 5 inches across, can be formed through the film 60 onthe side of the pad 30 closer to the box 20, that is the side oppositethe opposite the cavity in which the item to be shipped is to bepositioned. These apertures are not present on the side facing thecavity in which the item to be shipped is to be positioned; the film 60on that side of the pad 30 is unbroken. The apertures can prevent pocketfrom acting like a balloon when the pad is inserted into the box—thefilm 60 can collapse against primary surfaces of the panels.

In some implementations, a pad includes only one panel in the pocketformed by the film. However, referring to FIGS. 7A and 7B,cross-sectional side views, in some implementations, the pad 30 includesmultiple panels 50. The panels 50 are stacked along their thicknessdirection, and not arranged side-by-side. This permits fabrication of athicker pad 30, thus increasing the thermal insulating capability. Forexample, this permits the total thickness of the pad to be about 1-4inches. In addition, avoiding gaps between that would occur withside-by-side panels can improve thermal insulation. In the example shownin FIG. 7A, there are three panels 50 a, 50 b and 50 c, but there couldbe just two panels or four or more panels.

For a multi-section panel, when the panels 50 are scored, the scoring 56can be performed by compressing the stack of panels along a line (ratherthan cutting the panels). As a result, in the scored region some of thepanels can be driven partially into the underlying panel.

Where the panels 50 are multi-section panels, sections at each end ofthe pad can be shorter than the section immediately underneath tocompensate for the stacking arrangement such that the ends of panels aresubstantially aligned. For example, as shown in FIG. 7A, section 52 b 1is shorter than the underlying section 52 a 1. In addition, the ends ofthe sections at the end of each pad can be cut at an angle. For example,as shown in FIG. 7A, the ends of sections 52 a 1 and 52 b 1 can be cutat an angle, e.g., a 45° angle. Thus, as shown in FIG. 7B, when themulti-section panels are folded inwardly, e.g., to form the U-shapedpad, the ends of the panels 50 align.

In the various implementations discussed above, the individual pads 30will rest on one another when inserted in the cavity of the box 20.However, the pads 30 are not fixed to each other, e.g., the pads are notsecured by adhesive or interlocking components to each other.

In some implementations, the solid compostable panels could be used, butwithout enclosing or coating the panels with a water-proof film. FIG. 8is an exploded perspective view of an example of another implementationof an insulated shipping container 10. The shipping container 10includes a recyclable box 20 and multiple thermally insulatingcompostable panels 50 that fit inside the interior cavity 22 of the box20. The panels 50 are shaped such that when positioned in the box 20they provide an interior space to receive the item and optionally acoolant, e.g., ice, dry ice or a gel pack.

Optionally, a recyclable interior box 90, e.g., a cardboard box, can fitinto a space defined by the interior of the panels 50. In this case, theinterior cavity of the interior box 90 provides the space to receive theitem and optionally a coolant. The interior box 90 can provideadditional thermal insulation, and can protect the panels from water,e.g., condensation caused by coolant. However, as noted above, the itemand coolant could be placed into the interior space, without using theinterior box.

Each panel 50 can be fabricated as discussed above, e.g., formedprimarily of extruded milled sorghum, so as to be compostable. However,the panels are not coated with, enclosed in, or otherwise protected by awater-proof film. Rather, the panels 50 are simply inserted into thecavity 22 in the box. One or more of the panels 50 can be amulti-section panel, which is scored as discussed in the variousimplementations discussed above, and then folded at right angle toprovide multiple rectangular plates.

In the implementation shown in FIG. 1, the thermally insulating panels50 include a bottom panel 82, a collar 84, and a top pad 86.

The bottom panel 82 has a length and width that match the bottom of thebox 20, or are slightly smaller, e.g., by about an ⅛ inch tolerance, sothat bottom panel 82 fits snugly at the bottom of the cavity 22 on thebottom of the box 20.

The collar 84 includes a single panel that is folded into fourrectangular plates. The four rectangular plates provide four wallmembers 40, which are equivalent to the wall members discussed withrespect to FIG. 1, but without the compostable or recyclable film. Eachwall member 40 has a height (in the vertical direction) about equal tothe height of the box 20, less the combined thickness of the top panel82 and bottom panel 86. Each wall member 40 has a width (in the lateraldirection) that matches the adjacent side wall 24 of the box 20, or isslightly smaller, e.g., e.g., by about an ⅛ inch tolerance. Thus, thecollar 84 fits snugly into cavity 22 on top of the bottom panel 82, witheach wall member 40 adjacent, e.g., in contact with, one of the sidewalls 24.

The top panel 86 has a length and width that match the top of the box20, or are slightly smaller, e.g., by about an ⅛ inch tolerance, so thatthe perimeter of the top panel 86 can sit on the wall members 40 of thecollar 84 and the top panel 86 itself fits snugly at the top of thecavity 22.

Although FIG. 8 illustrates a configuration for the panels 50 that issimilar to the configuration of pads 30 in FIGS. 1 and 2A-2G, otherconfigurations for the panels, e.g., equivalent to those shown in FIGS.3A-3I, FIGS. 4A-4D, FIGS. 5A-5H, or 6, are possible. Similarly, multiplepanels 50 can be stacked, e.g., as illustrated in FIGS. 7A-7B, but againwithout the compostable or recyclable film.

Although milled sorghum is discussed above, as noted it may be possibleto form the panel out of a grain starch, such as corn starch or wheatstarch. However, sorghum is generally superior in that it can providesuperior thermal insulation than corn starch. In addition, theparticulates of milled sorghum may be more amenable to extrusion.

Referring to FIG. 9, although in some implementations multiple panelscan be stacked without being joined, it is also possible for multiplepanels 50 to be stacked and laminated together. This can increase thetotal thickness of the resulting panel, e.g., to 1 to 3 inches thick.The stacked panels can be joined by a thin layer of compostable adhesive100.

FIGS. 10A and 10B illustrate another implementation of a pad 30 that isparticularly easy to assemble and insert into a shipping container, andcan provide insulation for the floor and four sides of a shippingcontainer. The pad 30 includes a panel 50 that is enclosed in a pocket62 formed by a film 60. The panel 50 can be a single panel.Alternatively, the panel 50 can include multiple stacked layers.However, if multiple independently slidable panels are present, theyshould be stacked vertically within the pocket rather than spaced apartlaterally.

As shown in FIG. 10B, the panel 50 is shown folded in half and insertedinto the pocket 62 formed by the film 60. A narrower edge 120 of thepanel 50 can be positioned adjacent an edge 132 of the pocket 62. Thepanel 50 can fill about half of the pocket 62. At this stage, the filmsurrounds the panel, but isn't positioned in any interior space formedby the panel.

FIG. 11 illustrates the panel 50 in an unfolded state. The panel 50includes two wider sections 120, 122 that are connected by a narrowersection 124. Each section 120, 122, 124 can be rectangular. The firstwider section 120 includes a central portion 120 a and two flaps 120 b,120 c that project past the narrower section 124 on each side by a widthW1. Similarly, the second wider section 122 includes a central portion122 a and two flaps 122 b, 122 c that project past the narrower section124 on each side by a width W2. The total of W1+W2 is between and two(1-2) times than the distance D between the two wider sections 120 a,120 b, i.e., across the narrow section. The width W1 can be equal to thewidth W2.

In some implementations, the panel 50 is scored along the junctionbetween the narrow section 124 and each wider section 120, 122, e.g., asshown by score lines 56 a. In some implementations, the panel is scoredalong the junction between each flap 120 b, 120 c, 122 b, 122 c, and therespective central portion 120 a, 120 b of the respective wider section120, 122, e.g., as shown by score lines 56 b. In some implementations,the narrower section 124 is scored across its width (i.e., parallel tothe line along which the narrower section 124 is joined to the widersections 120, 122), e.g., as shown by score line 56 c. The score in thenarrower section 124 can be located at the midpoint of the narrowersection 124 between the wider sections 120, 122.

The panel 50 can be fabricated by being molded, e.g., injection molded,into the “I” shape with wider and narrower sections, or the panel 50 canbe fabricated as a rectangular body and then recesses cut out onopposite edges of the body sides to define the narrower section 124.

To initially assemble the pad, the panel is folded in about half. Forexample, the panel can be folded along the midline of the narrowersection 124, e.g., along the score 56 c. The folded panel 50 is thenenclosed in the film 60. The film has a width (measured parallel to thefold) about equal to the panel 50, but has a length (measuredperpendicular to the fold) slightly larger than about twice that of thefolded panel.

As shown in FIG. 12, to enclose the panel 50, the panel 50 can beinserted into a bag of film 60 that is open at one end. The open end ofthe bag of film 60 can then be sealed, providing the assembly shown inFIGS. 10A and 10B. Alternative, the panel 50 can be inserted into a tubeof film 60 that is open at opposite ends, and the two opposite ends ofthe tube can then be sealed. Alternatively, the panel 50 can be placedbetween two sheets of the film, and the edges of the film can be sealed,e.g., along the entire perimeter of the panel.

Sealing of the film 60 can be performed by heat-sealing, althoughadhesive bonding might also be practical. A suitable sealing temperaturefor heat-sealing is above 100° C. Excess film outside the seal can becut away.

The pad 30 now includes a sealed bag provided by the film 60, and thepanel 50 is sealed inside the pocket formed by the bag of film 60. Thepad 30 can be shipped to customers in this form.

The pad 30 can then be folded into a box-like shape and then insertedinto a shipping container by a customer or by a vendor. Referring toFIG. 13A. if the panel 50 is if folded, then it is unfolded. While stillinside the film 60, the panel 50 is refolded at right angles along thelines where the narrower section 124 is joined to the wider sections120, 122, e.g., along scores 56 a.

Then, as shown in FIG. 13B, the flaps 120 b, 120 c, 122 b, 122 c arefolded inwardly, e.g., along scores 56 b, so that flaps from each widesection 120, 122 are adjacent. So the edge of flap 120 b is adjacent theedge of flap 122 b, and the edge of flap 120 c is adjacent the edge offlap 122 c.

As such, the panel 50 now forms a generally rectilinear box 130 that isopen at the top, with the narrower section 124 forming the bottom, thecentral sections 120 a, 122 b of the two wider sections 120, 122 formingtwo opposite side walls, the two flaps 120 b, 122 b from each widersection 120, 122 providing one side wall, and the other two flaps 120 c,122 c from each wider section 120, 122 providing the remaining sidewall.

Finally, as shown in FIGS. 13C and 13D, the end of the bag of film 60adjacent the open end of the box 130 is pushed inwardly, as shown byarrow A in FIG. 13C, until the bag of film lines both the outer surfaceand the inner surface of the box 130, e.g., as shown in FIG. 13D. Theshape and tension in the film 60 may be such that the bag of film 60serves to retain the panel 50 in the folded box configuration.Alternatively, the panel 50 can be secured in the folded boxconfiguration with adhesive or tape. The pad can now be inserted into ashipping container. Alternatively, the pad may be inserted into ashipping container before the end the bag is pushed inwardly, and theend of the bag of film can be pushed inwardly with the containerretaining the panel 50 in the folded box configuration.

Such a pad is very easy to manufacture, having only limited parts andnot requiring complex cuts or shape, and is easy for a customer orvendor to assemble into proper shape as packaging for the shippingcontainer.

FIGS. 14-15 illustrate an implementation of a pad that similar to theimplementation of FIGS. 11-13D, but rather than the panel having recessthat defines a narrow section, a T-shaped slit is formed on each side ofthe panel. Features otherwise not described can be assumed to be thesame as the implementation of FIGS. 11-13D.

The panel 50 includes two sections 120, 122 that are connected by athird section 124. The section 124 can be rectangular, whereas thesections 120, 122 can be U-shaped.

A T-shaped slit 130 is formed, e.g., cut or stamped, on each side of thepanel 50. The T-shaped slit 130 includes a first slit 132 that extendsinwardly from the edge of the panel 50 to form the stem of the “T”, anda second slit 134 at the inner end of the first slit and that extendsperpendicular to the first slit 132 to form the cross of the “T”. Thefirst slit 132 extends along the midline, thus separating a portion ofthe sections 120, 122 from each other. The second slit 134 defines twoopposing edges of the third section 124, and defines end flaps 120 d,120 e, 122 d, 122 e, as described further below. The length L1 of thefirst slit 132 can be between one-half and one (½ to 1) times the lengthL2 of the second slit 134.

Similar to the embodiment of FIG. 11, the panel 50 of FIG. 14 can becovered with the film 60 to provide the pad 30, and the panel 50 can befolded into a box-like shape.

Referring to FIG. 15, if the panel 50 is if folded along the mid-line 56c, then it is unfolded. While still inside the film 60, the panel 50 isrefolded at about right angles along the lines 56 b that are collinearwith the second slits 134; this folds the flaps 120 b-120 e, 122 b-122 einwardly. The flaps 120 d, 120 e, 122 d, 122 e can then be foldedinwardly along lines 56 a that extend parallel to the first slit 132 andintersect the ends of the second slit 134. Then the flaps 120 a, 122 acan be folded inwardly along lines the lines 56 a; this brings the panelinto a box-like configuration. Depending on the relative length of L1 toL2, some or all of the flaps that form the side walls may overlap. Forexample, flaps 120 c, 122 c can partially or entirely overlap, and flaps120 b, 122 b can partially or entirely overlap. In addition, the endflaps 120 d, 120 e, 122 d, 122 e will overlap a portion of the floor ofthe box that is defined between the fold lines 56 a.

Some or all of the lines along which the panel is folded can be scored.

It should be understood that although various terms such as “top”,“bottom”, “vertical” and “lateral” are used, these terms indicaterelative positioning of components under the assumption that an openingto the box 20 is at the top, and don't necessarily indicate anorientation relative to gravity; in use, or even during assembly, thecontainer 10 could be on its side or upside down relative to gravity.The term “slightly” indicates no more than about 5%, e.g., no more than2%.

A number of embodiments have been described. Nevertheless, it will beunderstood that various modifications may be made without departing fromthe spirit and scope of the invention. Accordingly, other embodimentsare within the scope of the following claims.

What is claimed is:
 1. A thermal insulation article, comprising: athermally insulating pad shaped to be positioned in a cavity of arectangular prism shipping container, wherein the pad includes a solidcompostable panel formed primarily of starch and/or plant fiber pulpthat holds together as a single unit, and a water-proof orwater-resistant film forming a pocket enclosing the panel, wherein thepanel is a single unitary body that comprises a first section, a secondsection, and a third section connecting the first section to the secondsection, the first and second section each having a central portion andtwo flaps that extend from the central portion beyond the third section,and wherein the panel is foldable into an open box with a narrow sectionproviding a floor of the box, central portions of the first and secondsection providing opposing first and second side walls of box, a firstpair of flaps from the first and second section providing a third sidewall of the box, and a second pair of flaps from the first and secondsection providing a fourth side wall of the box opposite the third sidewall.
 2. The article of claim 1, wherein the panel is formed of amaterial sufficiently soft to be manually folded.
 3. The article ofclaim 1, wherein the panel is scored to assist at least some folds. 4.The article of claim 1, wherein the two flaps that extend from thecentral portion are a first two flaps, and wherein the first and secondsection each have a second two flaps that extend from the first twoflaps, the second two flaps being foldable inward to overlap a portionof the floor provided by the third section.
 5. The article of claim 1,wherein the panel is formed primarily of starch.
 6. The article of claim5, wherein the starch comprises a grain starch, a root starch, avegetable starch, or combinations thereof.
 7. The article of claim 1,wherein the panel is formed primarily of plant fiber pulp.
 8. Thearticle of claim 7, wherein the plant fiber pulp comprises fibers fromwood, corn, cotton, coconut or flax.
 9. The article of claim 1, whereinthe panel has a uniform homogenous composition.
 10. The article of claim1, wherein the panel has a thickness between of about ¼ and 1 inch. 11.The article of claim 1, wherein one or more surfaces of the panel arecorrugated.
 12. The article of claim 1, wherein the film is water-proof.13. The article of claim 12, wherein the film is compostable.
 14. Thearticle of claim 12, wherein the film comprises polyethylene.
 15. Thearticle of claim 1, wherein the film is paper.
 16. The article of claim15, wherein the film comprises a water-resistant or water-proof coatingon the paper.
 17. The article of claim 16, wherein the coating compriseswax.